1999 DODGE RAM Transfer case

Governor pressure is monitored electronically and is used to
control transmission shifting. Electronic control system consists of
Powertrain Control Module (PCM), governor pressure solenoid, governor
pressure sensor, transmission fluid temperature sensor, OD (Overdrive)\
OFF switch, Throttle Position (TP) sensor and output shaft speed
sensor.
NOTE: Governor pressure sensor may also be referred to as governor
pressure transducer. Transmission fluid temperature sensor
may also be referred to as transmission fluid temperature
thermistor. Output shaft speed sensor may also be referred to
as transmission shaft speed sensor or shaft speed sensor.
Transmission shifting is controlled by throttle pressure and
governor pressure. Governor pressure is generated by electronic
components through control of line pressure. Transmission will not
upshift into 4th gear under the following conditions:
* 3rd gear upshift is not complete.
* OD OFF switch is in OFF position.
* Throttle is at 3/4 to WOT position.
* Vehicle speed is too low for 3-4 upshift.
* Transmission fluid temperature is less than 50
F (10C) or
greater than 250F (121C).
* Battery temperature is less than 5F (-15C).
OPERATION
POWERTRAIN CONTROL MODULE (PCM)
The PCM controls Torque Converter Clutch (TCC) operation,
overdrive clutch operation and the governor pressure solenoid. The PCM
determines shift points and TCC operation based on input signals
received from transmission fluid temperature sensor, output shaft
speed sensor, Crankshaft Position (CKP) sensor, Vehicle Speed Sensor
(VSS), Throttle Position (TP) sensor and battery temperature sensor.\
There are 4 governor pressure curves programmed into the PCM.
Governor pressure curves allow the PCM to adjust governor pressure for
varying conditions. One governor pressure curve is used for operation
when transmission fluid temperature is at or less than 30
F (1C). The
second governor pressure curve is used for operation when transmission
fluid temperature is at or greater than 30
F (1C) during normal city
operation or highway driving. The third governor pressure curve is
used for operation during wide open throttle (WOT). The fourth
governor pressure curve is used for operation when transfer case is in
low range.
The PCM controls TCC operation by operating the lock-up
solenoid located on the valve body. Lock-up solenoid may be referred
to as TCC solenoid. If OD switch is in the ON position, the TCC will
lock-up once transmission is in 4th gear with vehicle speed greater
than 45 MPH. If OD switch is in the OFF position, the TCC will lock-up
once transmission is in 3rd gear with vehicle speed greater than 35
MPH at light throttle application. When OD switch is in the OFF
position, the OD light on instrument panel will be illuminated.
The PCM prevents TCC operation and overdrive operation when
transmission fluid temperature is less than 50
F (10C). If
transmission fluid temperature exceeds 260F (126C), the PCM will
cause a 4-3 downshift and engage the TCC. The OD light will be
illuminated when the downshift occurs. Transmission will not upshift
until transmission fluid temperature decreases to approximately 230
F
(110F).

step.
7) Turn engine off. Drain transmission fluid and remove oil
pan. Inspect oil pan for burnt oil and debris. Repair transmission as
necessary. See appropriate AUTOMATIC TRANSMISSION OVERHAUL article. If
transmission is okay, no problem is found at this time, see INACTIVE
DTC CONDITION under SELF-DIAGNOSTIC SYSTEM. Testing is complete.
8) Leave gauges connected. Replace 3-4 shift solenoid.
Replace transmission pan and fill with fluid. Start engine and allow
engine and transmission to reach normal operating temperature. Using
scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear
while monitoring pressure gauges. Governor pressure should rise to
greater than 20 psi (1.4 kg/cm
) and O/D pressure should rise to
greater than 40 psi (2.8 kg/cm). If pressures are as specified, no
problem is found at this time. Testing is complete. If pressures are
not as specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL
article, paying attention to seals and clutches related to O/D clutch.
DTC P1740: TCC OR O/D SOLENOID PERFORMANCE (BR BODY - DIESEL)
Circuit Description
Torque Converter Clutch (TCC) and overdrive clutch are tested\
when Powertrain Control Module (PCM) requests TCC engagement in 3rd
gear and overdrive. Code will set if expected RPM drop is not achieved
while attempting to engage TCC and/or overdrive. Code indicates
malfunctioning torque converter or overdrive clutch.
Possible Causes
* Fluid level or quality problem.
* Transmission wiring and connector defective.
* Transmission mechanically defective.
* Low fuel level.
* Trans temperature below 32
.
* Transfer case is in low range.
* Engine RPM trouble codes set.
* Misfire trouble code set (DTCs P0300-P0306).
* Output shaft speed trouble code set.
* PTO is engaged.
* TPS codes set (DTCs P0121-P0123).
* Torque converter defective.
Diagnostic Procedures
1) Using scan tool, read DTCs. If DTC SPECIFIC GOOD TRIPS
counter is not displayed or displayed count is not "0", go to step
16). If DTC SPECIFIC GOOD TRIPS counter is displayed and displayed
count is "0", go to next step.
2) If any DTCs listed are present, perform appropriate
test(s). See TCC OR O/D SOLENOID TESTS table. If no DTCs are present,
go to next step.
TCC OR O/D SOLENOID TESTS









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DTC Message Test
CAMSHAFT POSITION SENSOR SIGNAL .......................... ( 1) P0341
P/N SWITCH STUCK IN PARK OR IN GEAR .......................... P1899
Any Throttle Position Sensor (TPS) DTC ......................... ( 1)
Any Misfire DTC ................................................ ( 1)
Any Engine RPM DTC ............................................. ( 1)
Any Output Shaft Speed Sensor DTC .............................. ( 1)
TRANS 12-VOLT SUPPLY RELAY CNTRL CIRCUIT ..................... P1765
TORQUE CONVERTOR CLUTCH SOLENOID/TRANS RELAY CIRCUITS ........ P0743
TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUITS ................ P0753

(1) - See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.








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3) Ensure fuel tank is at least 1/4 full. If fuel level is
too low, correct fuel level and retest. If fuel level is okay, go to
next step.
4) Ensure transfer case is not in low range. Shift transfer
case out of low range. If transfer case is not in low range, go to
next step.
5) Ensure PTO is not engaged. Disengage PTO. If PTO is not
engaged, go to next step.
6) Ensure transmission fluid temperature is above 32
F (0C).
Warm transmission to normal operating temperature. If transmission
fluid temperature is above 32
F (0C), go to next step.
7) Turn ignition on. Using scan tool, build a custom display
with engine RPM, output shaft SPD, TCC solenoid, O/D solenoid and
throttle position. Set overdrive to off position. Road test vehicle
and reach a steady speed of 55 MPH with a minimum throttle opening
voltage of 1.15 volts for 20 seconds. Note shift patterns while
vehicle is attaining speed. If engine RPM is within 60 RPM of output
shaft speed RPM, go to next step. If engine RPM is not within 60 RPM
of output shaft speed RPM, go to step 15).
8) If output shaft speed RPM is greater than engine RPM, go
to next step. If output shaft speed RPM is equal to or less than
engine RPM, go to step 15).
9) Road test vehicle and reach a steady speed of 55 MPH and
engage overdrive. If engine RPM is 69 percent of output shaft speed,
go to step 15). If engine RPM is not 69 percent of output shaft speed,
go to next step.
10) Connect a 0-300 psi (0-21 kg/cm
) pressure gauge to
transmission Overdrive (O/D) clutch pressure test port. Connect a
second 0-300 psi (0-21 kg/cm
) pressure gauge to transmission governor
pressure test port. See appropriate AUTOMATIC TRANSMISSION OVERHAUL
article. Ensure engine and transmission are at normal operating
temperature. With an assistant, test drive vehicle. Using scan tool,
select GOV and 3-4 SHIFT VALVE SYSTEM TEST. Select 4th gear while
monitoring pressure gauge. Governor pressure should rise to greater
than 20 psi (1.4 kg/cm
) and O/D pressure should rise to greater than
40 psi (2.8 kg/cm). If pressures are as specified, go to next step.
If pressures are not as specified, go to step 13).
11) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
12) Drain transmission fluid and remove oil pan. If
transmission fluid is burnt or has excessive debris, repair as
necessary. If transmission fluid is okay, go to step 23).
13) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
14) Leave gauges connected. Replace 3-4 shift solenoid. Start
engine and allow engine and transmission to reach normal operating
temperature. Using scan tool, select GOV and 3-4 SHIFT VALVE SYSTEM
TEST. Select 4th gear while monitoring pressure gauges. Governor
pressure should rise to greater than 20 psi (1.4 kg/cm
) and O/D
pressure should rise to greater than 40 psi (2.8 kg/cm). If pressures
are as specified, testing is complete. If pressures are not as
specified, see appropriate AUTOMATIC TRANSMISSION OVERHAUL article,
paying attention to seals and clutches related to O/D clutch.
15) Check transmission fluid for proper level and for any
debris. Fill or repair transmission as necessary. If fluid level and
condition are okay, go to next step.
16) Start engine. Using scan tool, perform TCC SYSTEM TEST.

13) On A/T models, ensure all electrical connectors are clean
and properly connected to electrical plugs on transmission case. On
all models, check for loose or defective electrical connections on
starter and starter solenoid.
MECHANICAL INSPECTION
Compression
Manufacturer does not provide information for checking
compression.
FUEL SYSTEM
AIR IN FUEL SYSTEM
NOTE: Air in the fuel system may cause hard starting, rough
running, excessive smoke, poor engine performance, engine
misfire, poor fuel economy and fuel knock. Air may enter fuel
system whenever fuel supply lines, fuel filter/water
separator, fuel injection pump, fuel injectors or high
-pressure fuel lines are removed or disconnected.
1) Inspect all low-pressure fuel lines from fuel tank to fuel
transfer pump, fuel heater and fuel filter/water separator for signs
of leakage. Inspect all high-pressure fuel lines for signs of leakage.
See FUEL INJECTOR & HIGH-PRESSURE FUEL LINES under FUEL SYSTEM.
2) After repairing fuel leak, bleed air from fuel system. See
FUEL LINE BLEEDING under FUEL SYSTEM in REMOVAL, OVERHAUL &
INSTALLATION - TRUCKS - DIESEL article.
FUEL HEATER
1) Fuel heater is located in fuel filter/water separator. See
Fig. 1 . Fuel heater uses a fuel heater temperature sensor for
controlling operation of the fuel heater.
2) A defective fuel heater may cause excessive wax build-up
in the fuel filter/water separator during cold ambient temperatures.
Wax build-up may cause hard starting, prevent engine from
accelerating, low power, Blue smoke or White smoke. For testing of
fuel heater and fuel heater temperature sensor, see SYSTEM & COMPONENT
TESTING - TRUCKS - DIESEL article.
FUEL HEATER RELAY
Ensure fuel heater relay, located in power distribution
center is installed correctly and that terminals are not corroded. For
fuel heater relay testing, see SYSTEM & COMPONENT TESTING - TRUCKS -
DIESEL article.
FUEL FILTER/WATER SEPARATOR
NOTE: A blocked or restricted fuel filter/water separator may cause
starting problems, prevent engine from accelerating, low
power or White smoke. If an excessive amount of water
collects in filter/separator in a short period of time, it
may be necessary to drain and clean fuel tank.
1) When ignition switch is first turned to ON position,
WATER-IN-FUEL (WIF) warning light should come on for 2 seconds to
perform bulb and wiring circuit test and then go off. WATER-IN-FUEL
(WIF) warning light is located on instrument panel, just below the

CLU TC H
1999 D odge P ic ku p R 1500
1998-99 CLUTCHES
CHRY - RWD - Trucks
Dakota, Ram Pickup
DESCRIPTION
Clutches on all models are dry, single-disc design.
Adjustment for wear is not possible. Clutch pedal is connected to
release fork through a hydraulic master cylinder and slave cylinder
and is not adjustable. Pre-lubricated clutch bearing is constant
running type. External adjustments cannot be made.
All models are equipped with a clutch pedal position switch.
The switch completes the circuit to the starter relay and is mounted
on clutch master cylinder push rod. The position switch is an integral
part of clutch master cylinder push rod and cannot be serviced
separately.
TRANSMISSION/TRANSFER CASE APPLICATION









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Transmission Transfer Case
Dakota
AX15, NV1500 & NV3500 .............................. NV231 & NV242
Ram Pickup
NV3500, NV4500, NV4500HD & NV5600 ..... NV231HD, NV241LD & NV241HD









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ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
NOTE: Clutches are a single, dry disc type. Adjustment for wear is
not possible. Clutch is actuated through hydraulic master
cylinder and slave cylinder, and is self-adjusting.
SHIFT LINKAGE ADJUSTMENT
NV231 (Dakota)
1) Shift transfer case into 4H position, and secure shift
lever in shift gate. See Fig. 1. Raise and support vehicle. Loosen
shift rod lock bolt at swivel. Ensure shift rod slides freely in
adjusting swivel.
2) Ensure transfer case range lever is in 4H position. Slide
adjusting swivel forward until shift rod contacts shift gate
crossover, then slide adjusting swivel back, allowing a .11-.20" (3-5
mm) gap between shift lever and shift gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m.). Lower vehicle, making sure all
wheels are off floor. Start engine. Shift transfer case through all
ranges to verify correct adjustment.
NV231HD, NV241LD & NV241HD (Ram Pickup)
1) Place shift lever into 2H position. Raise and support
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 2. Ensure
shift rod fits in swivel and does not bind.
2) Ensure transfer case shift lever is in 2H position. Lower
vehicle. Position shift lever in cab so distance between instrument

panel and 2H position dot in shift lever insert is 5.75" (14.6 cm).
Make measurement parallel to floor of vehicle.
3) Tighten shift rod lock bolt to 90 INCH lbs. (10 N.m).
Start engine. Shift transfer case through all ranges to verify proper
operation.
NV242 (Dakota)
1) Put shift lever into 4FT position and secure. Raise
vehicle. Loosen shift rod lock bolt at swivel. See Fig. 1. Ensure
shift rod slides freely in adjusting swivel.
2) Ensure transfer case shift lever is in 4FT position. Slide
adjusting swivel forward until shift lever contacts shifter gate
crossover then slide adjusting swivel back, allowing a 0.11-0.20" (3-5
mm) gap between shift lever and shift gate.
3) Center pin on adjusting swivel in shift arm and tighten
lock bolt to 90 INCH lbs. (10 N.m). Lower vehicle, making sure wheels
are off floor. Start engine. Shift transfer case through all ranges to
verify correct adjustment.
Fig. 1: Adjusting Transfer Case Shift Linkage (Dakota)
Courtesy of Chrysler Corp.

Fig. 2: Adjusting Transfer Case Shift Linkage (Ram Pickup)
Courtesy of Chrysler Corp.
TROUBLE SHOOTING
NOTE: For trouble shooting not covered in this article, see
appropriate table in TROUBLE SHOOTING article in GENERAL
INFORMATION.
Hydraulic system should not require addition of fluid under
normal circumstances. Reservoir fluid level will increase as normal
clutch wear occurs. Avoid overfilling or removing fluid from
reservoir. This will cause clutch release problems.
TESTING
CLUTCH PEDAL POSITION SWITCH
NOTE: The position switch is an integral part of clutch master
cylinder push rod and cannot be serviced separately.
Disconnect clutch pedal position switch electrical connector.
Depress switch. Using a DVOM, measure continuity between clutch pedal
position switch terminals No. 1 (Yellow/Red wire) and No. 2 (Dark
Blue/Yellow wire). If continuity exists, switch is okay. If continuity
does not exist, replace clutch master cylinder. See CLUTCH MASTER
CYLINDER under REMOVAL & INSTALLATION.

REMOVAL & INSTALLATION
TRANSFER CASE
CAUTION: When removing transfer case, DO NOT allow drive shafts to
hang free, as damage to "U" joints may result.
Removal (NV231HD, NV241HD & NV241LD - Ram Pickup)
1) Raise and support vehicle. Remove skid plate (if
equipped). Drain lubricant from transfer case if transfer case is
being repaired. Mark drive shafts and "U" joints for reassembly
reference. Disconnect speed sensor wires. Disconnect vent harness and
vent hose from transfer case switch.
2) Disconnect shift rod from grommet in transfer case shift
lever, or from floor arm, whichever provides easy access. Using slip
joint pliers, press rod out of lever grommet. See Fig. 8. Support
transmission with jackstand. Remove rear crossmember. Remove front and
rear drive shafts. Remove transfer case-to-transmission housing nuts.
Using transmission jack, support transfer case. Move transfer case
rearward until free of transmission. Remove transfer case from under
vehicle.
Removal (NV231 & NV242 - Dakota)
1) Shift transfer case into neutral. Raise vehicle. If
transfer case will be repaired, drain lubricant. Mark driveshafts and
"U" joints for reassembly reference. Support transmission with
jackstand. Remove rear crossmember and skid plate, if equipped.
2) Disconnect front and rear driveshafts at transfer case.
Disconnect transfer case linkage rod from shift lever. Disconnect
transfer case vent hose and electrical connectors. Support transfer
case with transmission jack. Remove nuts attaching transfer case to
transmission. Remove transfer case.
Installation (All Models)
To install, reverse removal procedure. If necessary fill
transfer case with MOPAR ATF Plus or Dexron-II. Tighten all nuts and
bolts to specification. See TORQUE SPECIFICATIONS table. Adjust shift
linkage, if necessary. See SHIFT LINKAGE ADJUSTMENT under ADJUSTMENTS.
Fig. 8: Removing Transfer Case Shift Mechanism (NV4500 & NV4500HD)
Courtesy of Chrysler Corp.
TRANSMISSION (DAKOTA)